Third Party Inspection for Fire Tube Boiler

The Third Party Inspection for Fire Tube Boiler article provides you information about fire tube boiler inspection and fire tube boiler test in manufacturing shop.

You may need to review this article in conjunctions of following article:

Inspection and Test Plan for Fire Tube Boiler

This content guides you about all necessary stages in the production of the fire tube boilers from the examination of certification of procurement sources to the final inspection, preservation and packing to despatch to site.

You need to take this point in account this article is written for a typical Fire Tube Boiler and might not be complete for special cases.

This content may be useful for second party inspectors, Fire Tube Boiler manufacture quality control personnel, engineering companies and purchasers as well.

All Fire Tube Boiler inspections and tests are carried out against the approved drawings, purchase order specifications, purchasers or company standards, and within the practices and rules of the country, state or province and any government decrees, laws, ordinance or regulation as may apply.

The applicable codes and specifications for the Fire Tube Boiler which is under construction process are:

  • Design code
  • Purchase order specification
  • Purchaser's standards
  • Approved drawings

And the applicable codes and standards are:

  • ASME I
  • ASME V

The applicable codes and standard may be based other international standards such as BS 2790 and etc. This content is general and can be useful if even the design code is different from ASME Code.

Required Documents for Third Party Inspector Review:

The list of documents normally is agreed in the Pre Inspection meeting which is hold several weeks before actual commencement of inspection work. The parties which are participated in this meeting are manufacture, purchaser and third party inspection agency representatives.

This already explained in the Inspection and Test Plan for Fire Tube Boiler article.

These are the list of documents which are normally agreed to be presented to the inspector:

  • Fire Tube Boiler Manufacture Quality Control Plan
  • Fire Tube Boiler Inspection and test plan
  • Fire Tube Boiler Data Sheet
  • Fire Tube Boiler Approved Drawings
  • Fire Tube Boiler Strength calculation sheets
  • Fire Tube Boiler Material Test Reports
  • Fire Tube Boiler Welding Specification Procedures (WPS) and Procedure Qualification Records(PQR)
  • Fire Tube Boiler Welding Map
  • Fire Tube Boiler Repair Procedure
  • Fire Tube Boiler Welders Qualifications Reports
  • Fire Tube Boiler NDE procedures
  • Fire Tube Boiler NDE Personnel qualifications Reports
  • Fire Tube Boiler Heat treatment procedure
  • Fire Tube Boiler Calibration Certificates for Test Equipment
  • Fire Tube Boiler Hydrostatic Testing Procedure and Water Quality Document
  • Fire Tube Boiler Preparation and Painting Procedure
  • Fire Tube Boiler Preservation, Packing and Shipping Procedure
  • Fire Tube Boiler Packing List

Third Party Inspection for Fire Tube Boiler- Material Inspection

The first actual inspection work in the Fire Tube Boiler is raw materials inspection. Based the ASME Code providing material test reports for Fire Tube Boiler plates is mandatory, for other components only the marking inspection will be enough.

But if purchase order has mandated the MTR to be provided for all components such as tubes, nozzle pipes, fittings and etc. then the manufacture provides them as well.

As mentioned in above, the original or authenticated copies of mill certificates for plates normally are available at manufacturer's premises.

The third party inspector examines these certificates for compliance with specifications and where appropriate, drawings.

The review includes checks on:

  • Certificate No.
  • Heat or cast No.
  • Chemical composition.
  • Mechanical properties.
  • Heat treated condition.
  • NDE applied and results.

Then inspector witnesses the plate material identification on the certificates against plate marking. It is also necessary to check with Fire Tube Boiler drawing datasheet, material list and other specification as appropriate.

The transfer identification to cut off plates also is checked.

Visual inspection for surface finish and probable defects are done and dimensional compliance with specification need also to be controlled.

When third party inspector carried out the material inspection, then provides inspection visit report, the report contains following items:

  • Confirmation of satisfactory document review
  • Record of the endorsement of certification reviewed/witnessed
  • Record of all non-conformities
  • Record of any tests witnessed and the result

Third Party Inspection for Fire Tube Boiler-Fabrication

When Fire Tube Boiler material inspection carried out and result was satisfactory or non-conformities closed by remedial action, then Fire Tube Boiler manufacture will be authorised to start fabrication.

The third party Inspector checks following points on Fire Tube Boiler based on the inspection and test plan (ITP) which is already agreed between purchaser and Fire Tube Boiler manufacture.

The inspection scope is determined in ITP, some clients prefer to have stringent control and put the TPI inspector in more “hold points” in fabrication activities and some others may take lesser “hold points” and put TPI much more in the review document.

This depend to the inspection budget which client assign for inspection, much more inspection will have much more costs and less risks and conversely less more inspection will have less costs but more risks.

For more detail review Inspection and Test Plan for Fire Tube Boiler article. There is draft ITP in this article which I believe it is the best practice for Fire Tube Boiler inspection.

The fire tube boiler third party inspector checks following:

  • Review weld procedure approval test and welder competency test records to ensure both are qualified in accordance with the code requirements.
  • Check plate identities and compare with mill certification details.
  • Witness the marking of test plates for identification before they are cut from the parent plate.
  • Inspect weld preparations in shell plates and end plates after forming. Ensuring that correct test plates have been attached.
  • As applicable to the welding method used in accordance with the boiler manufacturers quality plan visually inspect, Root runs on principal seams and plates, Completion of first side and back-gouged groove and After completion of all welding
  • Examine results of non-destructive testing and review radiographs.
  • Witness required tests on previously selected test plates.
  • Visually inspect tacked weld set ups on standpipes and similar attachments and review after completion of welding.
  • Final visual examination after completion of all work including witness of hydrostatic test and internal/external examination. Review of heat treatment records.

If third party inspector is not in hold or witness point in the ITP, then will review fire tube boiler manufacture quality control report in his/her coming visit or in final inspection day.

Third Party Inspection for Fire Tube Boiler-Post Hydrostatic Test

After depressurisation, boiler spaces are drained and where necessary dried.

If third party inspector is not in hold or witness point in the ITP, then will review fire tube boiler manufacture quality control report in his/her coming visit or in final inspection day.

Third Party Inspection for Fire Tube Boiler - Final Assembly

The fire tube boiler is checked by third party inspector for completeness and dimensionally examined to ensure that all attachments/supports are in the correct orientation.

Third Party Inspection for Fire Tube Boiler - Marking

Identification marks is checked by third party inspector and information stamped using low stress type stamps on pressure parts.

Third Party Inspection for Fire Tube Boiler - Name Plate Checking

The third party inspector checks the Fire tube boiler name plate and makes sure:

  • Material is compatible.
  • Contents of marking are in accordance with approved drawing and specifications and authority stamped as required.
  • Name plate is mounted on a bracket welded to a specified area of boiler, in accordance with the code requirement.

Third Party Inspection for Fire Tube Boiler - Painting and Coating Inspection

Surface preparation for painting is checked for the following points, according to specification by third party inspector:

  • Cleaning method (Blast or scraping and wire brushing)
  • Preparation grades
  • Freedom from weld spatter, blow-holes and other defects
  • Dry film thickness is checked according to specification

It is necessary surface condition to be free from pin-holes, runs damage and other discontinuity

Third Party Inspection for Fire Tube Boiler - Spares, Loose Items, Tools and Accessories:

The third party inspector controls spares, loose items, tools and accessories and makes visual and dimensional inspection for materials, workmanship and quantity according to purchase order specification and packing list.

Marking and/or Tag is checked for identification.

Third Party Inspection for Fire Tube Boiler - Reporting:

Third party inspector provides Inspection Visit Report (IVR) after each visit as well as a final report summarising the activities carried out during the vessel production in accordance with the contract requirements and circulated within the time limits specified in the contract.

The report is in the format required by the client and clearly indicates final acceptance or rejection of the Fire tube boiler.

Third Party Inspection for Fire Tube Boiler - Release Note:

When required by the contract or purchase order a release note is issued by third party agency and given to the manufacturer when the fire tube boiler have been finally accepted.

Third Party Inspection for Fire Tube Boiler - Packing, Marking and Shipping:

The following points are checked by the third party inspector:

  • Cleanliness and dryness of Fire tube boiler
  • Rust prevention for all machined surfaces
  • Protection for cover for all opening and protruding parts
  • Packing style and suitably for overseas transportation
  • Shipping marks and other markings and notification of welding prohibited, etc.

Third Party Inspection for Fire Tube Boiler -Final Book (Dossier)

The following final documents are reviewed and signed off by third party inspector:

As built, drawings if required, Manufacturer's data reports, Material certificate or certified mill test reports for all pressure parts, Material list or map, Heat treatment records (Temperature-time record chart during PWHT), NDE records, Hydrostatic test record, Hardness test record, Post weld heat treatment NDE, if specified, Name plate or other marks, Packing list and Spare parts and tool list

Related Articles:

Third Party Inspection for Water Tube Boiler, Pressure Vessel Inspections, Third Party Inspection for Reciprocating Compressor, Third Party Inspection for Centrifugal Pump, Third Party Inspection for Gas Turbine, Third Party Inspection for Steam Turbine, Third Party Inspection for Fan and Blower, Third Party Inspection for Centrifugal Compressor, Third Party Inspection for Shell and Tube Heat Exchanger, Third Party Inspection for Fin Tube Heat Exchanger, Third Party Inspection for Pressure Vessel, Third Party Inspection for Storage Tank, Third Party Inspection for Line Pipe, Third Party Inspection for Valve, Third Party Inspection for Steel Structure, Third Party Inspection Services, Third Party Inspection Agency, Third Party Independent Inspection, Third Party Quality Inspection

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